YOKOGAWA CENTUM CS 3000 Integrated Production Control System

YOKOGAWA CENTUM CS 3000 Integrated Production Control System: Architecture, Functionality, and Engineering Practice

1. System concept and solution: Optimizing operations from an enterprise perspective

CENTUM CS 3000 is the core platform of Yokogawa Electric's "Enterprise Technology Solutions" philosophy. This concept emphasizes starting from the perspective of an enterprise, using the latest technology to provide customers with the best solutions. This means that CENTUM CS 3000 is not just a process control system, but also a strategic information management platform that can integrate factory control and business management.

Open environment, optimize the entire enterprise: Traditional DCS mainly focuses on internal optimization within the factory. The CENTUM CS 3000 achieves easy connection with upper level enterprise resource planning systems (ERP) and manufacturing execution systems (MES) through its open interface. The Human Computer Interface (HIS) is based on a general-purpose PC (running on the Windows platform) and supports OPC (OLE for Process Control) interface as a standard, enabling the upper computer to easily access process data and achieve enterprise level optimization. At the same time, the system also provides software packages for connecting with factory automation (FA) systems and various programmable logic controllers (PLCs) to ensure synchronization of the entire production environment.

Flexible and durable hardware platform: The high reliability of the system controller is the key to determining factory productivity. CENTUM CS 3000 provides validated high reliability "paired backup" dual redundant controllers. Users can choose different types of control stations based on the size of the factory: standard control stations that handle a large number of I/O points, as well as compact control stations that can be distributed and support high-speed communication with subsystems. The system can support up to 256 control stations, suitable for medium to large factories. In addition, the system also supports intelligent field devices such as FOUNDATION Fieldbus, enabling control function delegation and rich device diagnostic information reading.

Reduce total cost of ownership and increase profits: The CENTUM CS 3000 is designed as an ideal replacement for existing systems with high cost-effectiveness. It can enhance and integrate existing DCS systems (such as CENTUM CS, CENTUM-XL, μ XL, etc.), protecting users' existing hardware, software, and knowledge investments. By using remote I/O units that can be installed near the site, wiring costs can be significantly reduced. At the same time, the integrated device management tool PRM (Plant Resource Manager) fully utilizes the communication capabilities of intelligent field devices to achieve efficient device management and maintenance, thereby significantly reducing the total cost of ownership (TCO) of the factory.

2. System architecture and core components

The system architecture of CENTUM CS 3000 is clear and modular, mainly composed of human-machine interface station, on-site control station, engineering station, and network.

Human Machine Interface Station: HIS is the core interface for operators to monitor and operate processes. It is divided into Console Type and Desktop Type. The console type HIS inherits the operability and functionality of traditional DCS, while integrating the latest PC technology, and can be configured with double-layer stacked LCD, touch screen, and dedicated eight operation key keyboard. Desktop HIS uses a general-purpose PC. The HIS software is based on Windows and not only supports specialized operations, but can also run general-purpose office software such as Excel on the same PC to achieve data analysis and report writing. Its graphical window can intuitively display the factory status, control panel, and overview objects.

On site control station: FCS is the core unit that executes process control logic. Yokogawa offers multiple FCS models to meet different application requirements:

FCS for FIO (KFCS, KFCS2, FFCS): Utilizing compact and diverse field network I/O modules. Its core is the field control unit (FCU), which is connected to local nodes through the ESB bus (Extended Serial Backboard Bus, up to 10 meters long) or to remote nodes through the ER bus (Enhanced Remote Bus, up to 185 meters or 2 kilometers long). Both CPU architecture and ESB/ER bus can choose single or double redundancy.

FCS for RIO (LFCS, LFCS2): Using field validated remote I/O modules, characterized by isolated channels and M4 screw wiring. FCU connects I/O nodes through RIO bus, using shielded twisted pair cables up to 750 meters in length, and up to 20 kilometers through bus repeaters or fiber optic links.

Compact FCS: including FFCS (FCU and Node Unit Integration) for FIO and PFC-H/- S/- E series for RIO. These compact controllers are typically installed near equipment or processes, making them ideal for communicating with subsystems.

I/O modules and wiring: FIO modules come in a variety of types, including non isolated/isolated analog input/output, thermocouple/thermistor input, digital input/output, pulse input, and modules that support the HART protocol. The wiring method is flexible and supports pressure clamp terminals (which can directly connect to on-site cables), KS cable adapters, and MIL cables. The RIO module is installed in different types of I/O module racks (Nests), and also supports various signal types such as analog, digital, thermistor/thermocouple, multiplexer, etc.

Network system: CENTUM CS 3000 adopts a dual layer network architecture.

V net: This is a real-time control system bus that connects sites such as HIS, FCS, Bus Converter (BCV), and Communication Gateway (CGW), with a speed of 10 Mbps. V net supports dual redundancy, using coaxial cable (YCB111, up to 500 meters) or dedicated cable (YCB141, up to 185 meters). By using bus repeaters and optical repeaters, V net can be extended up to 20 kilometers.

Ethernet: used to connect HIS, Engineering Stations (ENG), and upper level monitoring systems. It is responsible for synchronizing HIS databases, sending trend data files to monitoring computers, and conducting other non real time communications to reduce the load on V net.

3. High reliability and redundant design

For FCS with direct connection process, high availability is a basic requirement. CENTUM CS 3000 achieves redundancy at multiple levels:

CPU redundancy: In dual redundant FCS, processor cards work in pairs (one active and one standby). Each processor card has two CPUs inside, which perform the same control operations and compare the results. If the results are consistent, it is judged as normal; If there is inconsistency, it is judged as "CPU abnormality", and control is immediately switched to the backup processor card without interrupting control. The main memory adopts ECC (Error Correction Code) memory, which can automatically correct instantaneous bit reversal errors.

Bus redundancy: Both the ESB/ER bus in the FIO system and the RIO bus in the RIO system can be configured as dual redundancy. Two buses are used alternately. When one bus experiences an abnormality, the system will automatically switch to the other bus for communication and regularly test whether the abnormal bus has returned to normal.

Node redundancy: In I/O nodes, both the node interface module and the power module can achieve dual redundancy. The internal bus from the node interface module to each I/O module can also be configured as dual redundancy.

Power redundancy: Multiple models of FCS offer dual redundant power module options.

This multi-level and all-round redundant design ensures that even if a single component fails, process control will not be interrupted, greatly improving the availability of the system.

4. Powerful control and engineering functions

Control functions: FCS performs continuous control (PID, etc.), sequential control (logic diagram, sequence table, SFC), and complex calculations. The control function is built on "function blocks" that can be interconnected, similar to traditional instrument flowcharts. The Control Drawing option allows multiple functional blocks to be combined into one control function, facilitating engineering and maintenance. Sequential control supports program control and conditional control. SFC blocks and SEBOL (Sequence and Batch Oriented Language) are used to handle large-scale and complex sequence control.

Engineering environment: The engineering functions of CENTUM CS 3000 run on a general-purpose PC and can be shared with the operation monitoring function on the same PC, making it easy to switch between engineering and operation. Its core is the "System View", which displays all components (FCS, HIS, etc.) in the engineering database in a tree structure. Double clicking can launch the corresponding builder program.

Concurrent Engineering: Utilizing the Windows file sharing feature, multiple engineers are allowed to edit a project database simultaneously, greatly improving project efficiency.

Virtual testing: The Engineering Station (ENG) provides a "virtual testing" function that simulates the operation of the control station without actual FCS hardware. Engineers can perform verification immediately after completing a program segment without waiting for hardware to be in place.

Reusable engineering data: Engineering data can be easily reused between different stations or projects, which helps with standardized control and knowledge accumulation.

Online maintenance: The system supports online modification of control functions without affecting other unmodified parts, minimizing the impact on factory operations.

5. Deep integration of ProSafe RS safety instrumented system

The manual introduces the ProSafe-RS Safety Instrumented System (SIS) in a dedicated chapter, reflecting the CENTUM CS 3000's emphasis on factory safety.

Compliant with international standards: ProSafe RS is a safety instrumented system that meets the IEC 61508 standard, with a safety integrity level of SIL3, and has been certified by T Ü V Rheinland in Germany. As a prevention and mitigation layer in the "protective layer" model, it performs emergency parking, fire and gas protection, and other actions in the event of an accident to protect personnel, equipment, and the environment.

Seamless integration with CS 3000: ProSafe RS adopts the same architecture as CS 3000 and is directly connected through V net, achieving unified operating environment. Operators can use the same interface (window) as monitoring FCS to monitor the Safety Control Station (SCS), and FCS can also read SCS data just like reading data from another FCS.

High availability and security: One unique feature of ProSafe RS is its built-in dual redundancy matching and self diagnostic mechanism within a single CPU module and I/O module, allowing for SIL3 to be achieved with a single configuration. If a dual redundancy configuration is adopted, even if one module fails, the system can still maintain the safety level of SIL3, achieving high availability under high security.

Rich testing and diagnostic functions: ProSafe RS provides virtual testing (simulating SCS on SENG) and target testing (performing on real SCS, disconnectable I/O) functions. The SOER (Sequence of Events Recorder) function can capture event sequences at a resolution of 1ms and analyze them through the SOE Viewer, which is crucial for fault cause analysis.

6. Rich optional software packages and solutions

To meet specific needs, CENTUM CS 3000 offers a wide range of optional software packages, such as:

Batch Management (CS Batch 3000): Based on the ISA S88.01 standard, product related information (formula) is separated from equipment control information to achieve flexible management of multi variety and variable batch production.

Advanced Process Control Station (APCS): An advanced control station running on a general-purpose server, used to perform long cycle and computationally complex optimization control, complementing FCS's 1-second cycle control.

System Integration OPC Station (SIOS): As a gateway, it integrates process control systems (PCS) from other vendors into the CENTUM CS 3000 system through OPC servers, enabling data exchange and alarm reception.

Remote Operation and Monitoring Server: Utilizing Windows Server Terminal Services, allows remote PCs to operate and monitor through Ethernet or dial-up networks (without the need to connect to V net).

Other features include web monitoring, event viewer, Long Term Trend History Library (LTTH), and coordination with SmartPlant Instrumentation.